Part Number PLUS-E017-A/1206 User — Read important user safety information found on pages 2, 18, 19 and 20. Installation and service should only be performed by a qualified service technician. Retain this manual for future reference. PLUS 40/60/80 PLUS 100/110/119 • Installation • Startup • Maintenance • Parts Manual This manual must only be used by a qualified heating installer/service technician. Before installing, read all instructions, including this manual and any related manuals or supplements. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage. Indirect-Fired Water Heaters Series 3 PLUS Line GOLD PLUS 30/40/60/80
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Indirec Fired Water Heater Plus Indirect Fired Water Heater Manual
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Part Number PLUS-E017-A/1206
User — Readimportantusersafetyinformationfoundonpages2,18,19and20.Installationandserviceshouldonlybeperformedbyaqualifiedservicetechnician.Retainthismanualforfuturereference.
mixing valve, at hot water tap or water heater.Automaticmixingvalvemustbeselectedandinstalledaccordingtovalvemanufacturer’srecommendationsandinstructions.
Studies have indicated that dangerous bacteria, including legionellapneumophila,canforminthepotablewaterdistributionsystemifcertainminimum water temperatures are not maintained. Contact your localhealthdepartmentformoreinformation.
OverviewThis manual contains six sections, A through F.
Sections A, E and F apply to ALL GOLD Plus 30, 40, 60 or 80; PLUS 40, 60, or 80; and PLUS 100, 110, or 119 water heater installations, regardless of the boiler used. Section A gives guidelines for domestic water connections to the water heater. Section E lists replacement parts. Section F includes water heater dimen-sions and ratings.
Section B provides boiler-side piping, wiring and start-up information for instal-lations with Gas-fired boilers only. Notice that ALL Gas-fired boiler installations require primary/secondary piping, as shown in Part B.
Sections C and D provide boiler-side piping and wiring information for installa-tions with all boilers except Gas.
A. GenerAlinstAllAtion(AllwAterheAters) .......................... 6
A4. Waterheaterstart-upFilling the inner (domestic water) tank ...................................................................... 16Filling the outer (boiler water) tank ............................................................................ 16Start-up checklist ........................................................................................................ 17
A5. AdjustingwaterheatertemperatureSafety warning and General notes ............................................................................ 18Setting the thermostat — GOLD Plus 30/40/60/80 or Plus 40/60/80 ............... 19Setting the thermostat — PLUS 100/110/119 ............................................................ 19
A6. WaterheatermaintenanceMaintenance schedule — Annual service by qualified technician ........................... 20Maintenance schedule — Homeowner’s monthly maintenance ............................. 20Filling ........................................................................................................................... 21Draining ....................................................................................................................... 21Draining inner (domestic water) tank ........................................................................ 21Draining outer (boiler water) tank .............................................................................. 21
A7. RecirculationandheattracingMaintaining domestic water temperature in the supply piping ............................... 22Time delay at fixtures ................................................................................................. 22
Contents
(continued on next page)
� Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
Balancing .................................................................................................................... 22Components required ................................................................................................ 22Connecting to the water heater ................................................................................. 22
B. GAs-firedBoilerApplicAtions .............................................. 24
B1. Installsystemwaterpiping(spaceheating)System water piping methods ................................................................................... 25Boiler circulator .......................................................................................................... 25Sizing space heating system piping .......................................................................... 25Zoning with zone valves............................................................................................. 26Zoning with circulators ............................................................................................... 27
B2. Installboiler-to-waterheaterpipingCombined space heating/water heating applications ............................................... 28Dedicated water heating-only applications ............................................................... 28
B3. Fieldwiring— Gas-firedboilersonlyInstallation must comply with:................................................................................... 30Line voltage connections ........................................................................................... 30Wiring boiler circulator ............................................................................................... 30Wiring water heater circulator ................................................................................... 30Wiring a system circulator ......................................................................................... 31Routing line voltage wiring ........................................................................................ 31Low voltage connections ........................................................................................... 31Room thermostat (space heating) ............................................................................. 31Outdoor temperature sensor ..................................................................................... 31Water heater thermostat ............................................................................................ 31Additional limits .......................................................................................................... 31
B4. Start-up— Gas-firedboilersonlyFollow boiler manual .................................................................................................. 33Set space heating operation ...................................................................................... 33Water heater operation .............................................................................................. 33Water heater operation setup .................................................................................... 33Verify space heating operation .................................................................................. 33Verify water heater operation .................................................................................... 34Operating information ................................................................................................ 34Replace boiler jacket front door ................................................................................. 34
c. BoilerpipinG(except GAs) ...................................................... 35
MultiplewaterheaterapplicationsMultiple water heaters – water heater piping — Figures 26/27 ................................ 42Boiler water piping for multiple water heaters — Figure 28 ..................................... 43
SteamboilerapplicationsConnecting water heater to steam boiler .................................................................. 44Installation and start-up of water heaters connected to steam boilers .................... 44Steam boiler application piping and wiring (Figure 29) ............................................ 45
d. Boiler-sidewirinG&controls(except GAs) .... 46
Wiringrequirements ................................................................................................ 47Wiring requirements — Circulators ........................................................................... 47Wiring requirements — Zone Valves ......................................................................... 47Boiler models requiring domestic priority with GOLD Plus 30 ................................ 47
Zoningwithpumps:
ZoningwithWeil-McLaincirculatorzonecontroller(WMCR)• Weil-McLain circulator zone controller (Figure 30) ................................................ 48
Otheroptionsforforzoningwithpumps• Using priority zone pump (Figure 31) ..................................................................... 49• Using pump relays • Domestic priority with priority relay (Figure 32) .............. 50• Using pump relays • No domestic priority (Figure 33) ...................................... 51• Pump relays • Priority with 3-way valve & priority relay (Figure 42) ................. 60
Zoningwith4-wirezonevalves• No domestic priority (Figure 35) ............................................................................. 53• With or without domestic priority • Models 30/40/60/80 (Figure 37) ................ 55• With domestic priority • PLUS 100/110/119 (Figure 39) .................................... 57• With priority using 2-way priority valve • PLUS 100/110/119 (Figure 40) ......... 58
Zoningwith3-wirezonevalves• No domestic priority (Figure 36) ............................................................................. 54• With or without domestic priority • Models 30/40/60/80 (Figure 38) ................ 56• With domestic priority • PLUS 100/110/119 (Figure 39) .................................... 57• With domestic priority using 2-way priority valve (Figure 41) .............................. 59
e. replAcementpArts......................................................................................... 61GOLD Plus 30/40/60/80 or PLUS 40/60/80 .................................................. 62-63PLUS 100/110/119 ................................................................................................. 64-65
f. wAterheAterdimensions&performAncerAtinGsDimensions ................................................................................................................. 66Performance ratings ................................................................................................... 67Warranty ..................................................................................................................... 68
Code restrictions National Standard Plumbing CodeSinglewallheatexchangerinwaterheatercomplieswithNationalStandardPlumbingCode,providedthat:• boilerwater(includingadditives)ispracticallynon-toxic,havingtoxicityratingorclass
of1,aslistedinClinicalToxicologyofCommercialProducts,and• boiler water pressure is limited to maximum �0 psig by approved relief valve.
Toreduceriskofexcessivepressuresandtemperatures inwaterheater,installtemperatureandpressureprotectiveequipmentrequiredbylocalcodes,butno less thana combination temperatureandpressure reliefvalvecertifiedbyanationallyrecognizedtestinglaboratorythatmain-tainsperiodicinspectionofproductionoflistedequipmentormaterials,asmeetingtherequirementsforReliefValvesandAutomaticGasShutoffDevicesforHotWaterSupplySystems,ANSIZ21.22.Thisvalvemustbemarkedwithamaximumworkingpressureofthewaterheater.
A2 Water heater piping
1. Size T&P relief valve by the following specifications, unless they conflict with localcodes:• GOLDPlus�0/�0/�0/80or Plus�0/�0/80: �/�”NPTwithanAGARatingof
AnexpansiontankmayberequiredontheDHWpiping.SeeThermalexpansionWARNINGonpage1�.Failuretocomplycould result in severepersonal injury,deathorsubstantialpropertydamage.
AnexpansiontankmayberequiredontheDHWpiping.SeeThermalexpan-sionWARNINGonpage1�.Failuretocomplycouldresultinseverepersonalinjury, death or substantial propertydamage.
AnexpansiontankmayberequiredontheDHWpiping.SeeThermalexpan-sionWARNINGonpage1�.Failuretocomplycouldresultinseverepersonalinjury, death or substantial propertydamage.
AnexpansiontankmayberequiredontheDHWpiping.SeeThermalexpan-sionWARNINGonpage1�.Failuretocomplycouldresultinseverepersonalinjury, death or substantial propertydamage.
Water hammer Dishwashers,clotheswashers,andfast-closingpositiveshutoffvalvesincorporatedinthesystemallcontributetocreatingwatershock.Installawaterhammerarrestertopreventdamagetopipesandappliances.Seecontrolmanufacturer’sinstructionsforapplicationandinstallation.
Boiler water • Boilerwater(includingadditives)mustbepracticallynon-toxic,havingtoxicityratingorclassof1,aslistedinClinicalToxicologyofCommercialProducts.
• If antifreeze isused inboiler system, local codesmayrequireabackflowpreventeroncoldwatersupplyline.Useantifreezespecificallyintendedforhydronicheatingsystems.Inhibitedpropyleneglycolisrecommended.
Hot Water Can Scald!• Watertemperatureover12�°Fcancausesevere
burnsinstantly,ordeathfromscalds.• Feelwaterbeforebathingorshowering.• Consumer Product Safety Commission and
some states recommend temperature settingsof1�0°Forless.Settingthermostathigherthan1�0°Fsettingwillincreaseriskofscaldinjuryandcancauseseverepersonalinjuryordeath.
• Water heated to a temperature suitable forclothes washing, dish washing and other sani-tizing needs will scald and cause permanentinjury.
General notes • Householdwaterusagepatternswillaffectwatertemperatureatanyfaucetorshower.Occasionallychecktemperatureateachpointofuse,thenadjustthermostataccordingly.Alwaysrechecktempera-tureafteradjustingthermostat.
• Lowering the thermostat setting or installingautomaticmixingvalvesasindicatedinthesein-structionswillreducewatertemperaturelevels.Consultyourinstallerorservicetechnician.
Studieshaveindicatedthatdangerousbacteria, includinglegionellapneumophila,canforminthepotablewaterdistributionsystem if certainminimumwater temperaturesarenotmaintained.Contactyour localhealthdepartmentformoreinformation.
Setting the thermostat GOLD Plus 30/40/60/80 or Plus 40/60/80
Setting the thermostat PLUS 100/110/119
Water heater thermostat is factory set to its lowest tem-perature.Thearrowheadindicator onthelabelisthepreferredstartingpointforsettingtemperature.Thismayormaynotbesuitableforyourneeds.
Checkwatertemperatureatahotwaterfaucetimmediatelyafter first heating cycle. Further temperature adjustmentmaybenecessaryaswaterheatingsystemisused.Recheckwatertemperatureatfaucetafteradjustment.
Water heater thermostat is factory set to its lowest tem-perature.Thewhitefactorysettingmarkonthelabelisthepreferredstartingpointforsettingtemperature.Thismayormaynotbesuitableforyourneeds.
Checkwatertemperatureatahotwaterfaucetimmediatelyafter first heating cycle. Further temperature adjustmentmaybenecessaryaswaterheatingsystemisused.Recheckwatertemperatureatfaucetafteradjustment.
Atnotimeshouldboilerlimitcontrolbesetabove210°F.Thiscancauseseverepersonal injury, death or substantialpropertydamageifignored.
Atnotimeshouldboilerlimitcontrolbesetabove210°F.Thiscancauseseverepersonal injury, death or substantialpropertydamageifignored.
Adjusting water heater temperature continued
Factory Setting
A5
20 Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
Water heater maintenanceA6Maintenance
schedule – annual service technician
Annual service by qualified service technician to include:• Anyproceduresrequiredbylocalcodes.• Checkairventoperation.• Verifysystempressure.Airventingproceduremayrequireaddingwatertobringsystem
BeforeoperatingT&Preliefvalve,makesurenooneisinfrontoforaroundT&Preliefvalvedischargepiping. Hot discharge water cancause severe personal injury orsubstantialpropertydamage.
Ifantifreezeisusedinboilerwater,checkconcentration.Boilerwater(includingadditives)mustbepracticallynon-toxic,havingtoxicityratingorclassof1,aslistedinClinical Toxicol-ogy of Commercial Products.Inhibitedpropyleneglycolisrecommended.Followantifreezemanufacturer’sinstructions.
¾" 95 238 32 79 19 48 12 30NOTE: Select branch size and length for less than 31 seconds delay.
Maintaining domestic water temperature in the supply pipingTwooptionsareavailabletomaintainsupplytemperatureavailableatornearthefixturesonstoragewaterheatingsystems:
hotwaterandenergywastecausedduringthewaitingperiod,andtopreventdegradationof the systemsupplywater temperature.ASPErecommendsrecirculationwhenthedistance fromthewaterheatertothefurthestfixtureexceeds100feetorthetimelagforhotwatertoreachafixture(s)exceeds�0seconds.ConsultlocalcodesandAmericanSocietyofPlumbingEngineers(ASPE)DomesticWaterHeatingDesignManual,1998,forfurtherinformation.
Time delay at fixturesTable2isfromtheASPEDomesticWaterHeatingDesignManual,1998.Itshowsthetimerequiredforusablehotwatertoarriveatafixturebasedonthefixtureflowrate(availablefromindustryandmanufacturer’sdata)andthelengthanddiameterofthedead-endbranchpipesupplyingthefixture.Thetimelagshouldgenerallynotexceed�0seconds.Forresidentialandofficeapplications,theownermaypreferalimitof10seconds.
Onmostcommercialsystems,installthedevicesshowninFigure9,page2�,andanyotherdevicesorpipingmethods required by local codes. The check valvesarerequiredtopreventfixturesfromtakinghotwaterthroughthereturnlines.Shutoffvalvesareneededtoallowcleaningandreplacingbalancingdevices.Includestrainerstoremovesedimentwhichcoulddamagethepumpand/oraffecttheflowbalancingdevices.
Connecting to the water heaterInstallarecirculationdiptubeintheAUXtappingontop of the water heater. This requires mounting theT&PreliefvalveasshownforOption2inthepipingdiagrams,pages10and12.SeeFigure10,page2�,forthepipingrequiredtothewaterheater.
Figure 10 Recirculation connection at water heater
Figure 9
Recirculation components
Components1 Circulator — Little flow is required to maintain a temperature in the piping. Size of
circulator depends on minimum flow requirements of the tempering valve. Minimum flow rates of the tempering valve must be maintained.
2 Aquastat — Used to control the on-off position of the circulator. Aquastat is set 5° to 10° lower than mixed water outlet of the mixing valve (#7). The circulator cannot run continuously as bypass through the mixing valve will eventually allow the temperature on the piping to climb to the water heater temperature during draw periods.
3 – 6 Check valves — Assure the flow of water in one direction. Each check valve func-tions as follows: #3 and #4 prevent bypass in the event of pressure drop, #5 prevents thermal siphoning of hot water to the cold water supply, #6 prevents flow of cold water to the tempered water supply. A draw of tempered water will not result in flow of cold water into the return loop.
Operation• During period of normal use (fixtures on) — Circulator is off. There is no flow through
#6, there is flow through #5 equal to the flow at the fixtures, there is flow through #3 and/or #4 equal to flow at fixture.
• When all fixtures are off — Circulator is off. There is no flow through #3, #4, #5 or #6. Water temperature in piping is cooling.
• When temperature at aquastat #2 falls 10° below temperature to be maintained — Circulator is on. There is flow through #6 equal to the minimum required by the mixing valve, flow through #3 and #4 equals the flow of the circulator. There is no flow through #5.
• Aquastat reaches temperature — Circulator is off. There is no flow through #3, #4, #5 or #6.
Problems• Missing check valves #3 or #4 — Extreme pressure drop can cause reverse flow of
water; hot to cold supply or cold to hot supply.• Missing check valve #5 — Hot water can migrate from the water heater back through
the cold water supply.• Missing check valve #6 — Cold water can be forced back through the tempered water
supply when a fixture is opened.• No aquastat #2 — Pump runs continuously. Small amount of water will pass through
mixing valve. Eventually all hot water is flowing through valve. Recirculated water through cold port, hot water through hot port.
• Circulator too small — Mixing valve performance erratic.
2� Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
B Gas-fired boiler applications
OverviewFollow the guidelines in this section to install Gas-fired boilers with PLUS or PLUS indirect water heaters. Install the domestic water piping and water heater following the guidelines of Section A. See Sections C and D for other boiler applications.
B1. InstallsystemwaterpipingSystem water piping methods ................................................................................... 25Boiler circulator .......................................................................................................... 25Sizing space heating system piping .......................................................................... 25Zoning with zone valves............................................................................................. 26Zoning with circulators ............................................................................................... 27Combined space heating/water heating applications ............................................... 28Dedicated water heating-only applications ............................................................... 28
B2. Installboiler-to-waterheaterpipingCombined space heating/water heating applications ............................................... 28Dedicated water heating-only applications ............................................................... 28
B3. Fieldwiring— Gas-firedboilersonlyInstallation must comply with:................................................................................... 30Line voltage connections ........................................................................................... 30Wiring boiler circulator ............................................................................................... 30Wiring PLUS circulator ............................................................................................... 30Wiring a system circulator ......................................................................................... 31Routing line voltage wiring ........................................................................................ 31Low voltage connections ........................................................................................... 31Room thermostat (space heating) ............................................................................. 31Outdoor temperature sensor ..................................................................................... 31PLUS water heater thermostat ................................................................................... 31Additional limits .......................................................................................................... 31
B4. Start-up— Gas-firedboilersonlyFollow boiler manual .................................................................................................. 33Set space heating operation ...................................................................................... 33Water heater operation .............................................................................................. 33Water heater operation setup .................................................................................... 33Verify space heating operation .................................................................................. 33Verify water heater operation .................................................................................... 34Operating information ................................................................................................ 34Replace boiler jacket front door ................................................................................. 34
Allpipingmethodsshowninthismanualuseprimary/secondaryconnectiontotheboilerloop.Thesedesignsensureproperflow through the Gas boiler, forthemostefficientandreliableoperationoftheboilerandtheheatingsystem.Forotherpipingmethods,consultyourlocalWeil-McLain representative or refer toseparate Gasboilerpipingguides.
Expansion tank and make-up water1. Ensureexpansiontanksizewillhandleboilerand
system water volume and temperature.Allow �gallonsfortheboileranditspiping.
Undersizedexpansiontankscausesystemwater to be lost from relief valve andmake-upwatertobeaddedthroughfillvalve. Eventual boiler failure can resultdue to excessive make-up water addi-tion.
�. Connect the expansion tank to the air separatoronlyiftheseparatorisonthesuctionsideofthesystemcirculator.Alwaysinstallthesystemfillcon-nectionat the samepointas theexpansion tankconnectiontothesystem.
�. The piping drawings in this manual show onlydiaphragmexpansiontanks.Useonlybladder-typeordiaphragm-typetankswithPLUSindirectwaterheaterapplications.
The boiler-side piping must beequipped with a diaphragm- orbladder-typeexpansiontank,NOTaclosed-typeexpansiontank.Thisis necessary to allow venting airfromthetopoftheindirectwaterheaterboiler-side.
DONOTusetheboilercirculatorinanylocationotherthanthoseshowninthismanualortheboilermanual.Theboilercirculatorisselectedtoensureadequateflowthroughthe boiler.Failuretocomply could result in unreliable per-formanceandnuisanceshutdownsfrominsufficientflow.
Sizing space heat system piping1. SeeFigures12and1�,pages2�and2�,orthe
2. Connect water heater (domestic hot water) pip-ing to indirect storage water heater as shown inSectionAofthismanual.
The PhDControlModuleturnsoffspaceheatingduringwaterheaterheat-ing. The boiler circulator will turn off,preventinghotwaterfromcirculatingtothesystem.Theflow/checkvalveshownontheboileroutletpipingpreventsgrav-itycirculationintheboilerloopduringwaterheaterheating.
3 Boiler relief valve (see boiler manual for piping details)
4 Boiler relief valve discharge piping (see boiler manual for details)
5 Water heater circulator (see page 7 for suggested sizing)
6 Isolation valves
7 System circulator
8 Diaphragm (or bladder) type expansion tank (see page 3 for piping of closed-type expansion tank, if used)
9 Air separator [with automatic air vent only on systems using diaphragm (or bladder) type expansion tank]
10 Flow/check valves (with weighted seats to prevent gravity circulation)
11 Purge/drain valves
12 Boiler circulator
13 Zone valves, typical
20 Make-up water supply
21 Primary/secondary connection
NOTE 1: To ensure adequate flow rate through theboiler, use the following pipe size on allboilerlooppiping(connectingboilertoandfrom the primary/secondary connection,item21):
-80or -10�–1”orlarger.
-1��or -2�0–1¼”orlarger.
-�10–1½”orlarger.
Use at least the minimum piping sizeaboveandpipetheboilerusingonlypri-mary/secondarypipingasshown.Failuretofollowtheseguidelinescouldresultinsystemproblems.
�. Connect water heater (domestic hot water) pip-ing to indirect storage water heater as shown inSectionAofthismanual.
The PhDControlModuleturnsoffspaceheatingduringwaterheaterheat-ing. The boiler circulator will turn off,preventinghotwaterfromcirculatingtothesystem.Theflow/checkvalveshownontheboileroutletpipingpreventsgrav-itycirculationintheboilerloopduringwaterheaterheating.
NOTE 1: To ensure adequate flow rate through theboiler,usethefollowingpipesizeonallboilerlooppiping(connectingboilertoandfromthe primary/secondary connection, item21):
-80or -10�–1”orlarger.
-1��or -2�0–1¼”orlarger.
-�10–1½”orlarger.
Legend Figure 13
1 boiler
2 PLUS-Line indirect water heater
3 Boiler relief valve (see boiler manual for piping details)
4 Boiler relief valve discharge piping (see boiler manual for details)
5 Water heater circulator (see page 7 for suggested sizing)
6 Isolation valves
7 System circulator
8 Diaphragm (or bladder) type expansion tank (see page 3 for piping of closed-type expansion tank, if used)
9 Air separator [with automatic air vent only on systems using diaphragm (or bladder) type expansion tank]
10 Flow/check valves (with weighted seats to prevent gravity circulation)
11 Purge/drain valves
12 Boiler circulator
14 Zone circulators, typical
20 Make-up water supply
21 Primary/secondary connection
Use at least the minimum piping sizeaboveandpipetheboilerusingonlypri-mary/secondarypipingasshown.Failuretofollowtheseguidelinescouldresultinsystemproblems.
B1Gas
28 Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
Install boiler-to-water heater piping
Combined space heating/water heating applications1. Figure1� shows recommendedpipingbetween Gas
2. Table�,page29,usestherecommendedflowratesforthePLUSwaterheaterandminimumflowratesforthe Gas boiler to provide recommended water heater pipingandcirculatorsizing.Ifusinganothercirculator,verifyitisatleastequaltotheTacoselectiongiveninTable�,page29.For general information on head loss through boiler andboiler-to-waterheaterpiping,refertothe GasBoilerManual.
115°F 140°F GPM Rec. size Boiler Heater Piping TOTAL
Ultra-80
40 160 124
6.6 1" 5.8 1.0 2.4 9.2 007
60 168 132
80 176 140
100 190 155
110 210 175
119 230 190
Ultra-105
40 203 141
6.4 1" 5.9 1.0 2.3 9.2 007
60 211 162
80 219 170
100 230 185
110 250 205
119 270 225
Ultra-155
40 250 160
12.1 1¼” 11.4 1.0 4.5 16.9 0014
60 295 220
80 305 230
100 315 245
110 335 265
119 355 285
Ultra-230
40 240 170
13.5 1¼” 10.0 1.0 5.2 16.2 0014
60 335 220
80 430 325
100 440 335
110 460 355
119 480 375
Ultra-310
40 240 170
18.3 1½” 8.3 1.0 4.2 13.5 0014
60 335 220
80 580 410
100 590 435
110 610 465
119 630 485
Notes Tables 3 and 4 Figure 16 Pump curves for Taco circulators
Gas ThefollowingratingsareforUltraGasboilersonly,withsupplywatertemperatureat190°F.ForboilersotherthanUltraGas,seepage��forratings.
�0 Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
ELECTRICAL SHOCK HAZARD— For your safety, turn off electricalpower supplyat serviceentrancepanelbeforemakinganyelectricalconnectionstoavoidpossibleelectric shockhazard.Failuretodosocancauseseverepersonalinjuryordeath.
total electrical power requirements of connecteddevices.Seedevicemanufacturers’specificationsandthermostatinstructionsfordetails.
Outdoor temperature sensor1. Outdoorresetoperationappliesonlytocombined
spaceheating/waterheatingsystems.
2. Connectoutdoor temperature sensor (Figure19,item�)betweenterminals1and2toenableout-door reset operation of the Gasboiler. Iffixed-temperature operation is required, do notinstalloutdoorsensor.
�. Installasummer/winterswitch(Figure19,item�)acrossterminals1and2toforcefixed-temperatureoperation during summer months. (When theswitch is closed, boiler will attempt to maintainconstanttemperature.)
Water heater thermostat1. Connect PLUS water heater aquastat terminals
“C” and“1” to Gas boiler low voltage ter-minal stripbetween terminals� and� (Figure9,item�).
Additional limits1. Connect additional limit controls and interlocks
betweentheterminalsshowninFigure19.
2. Controls connected between terminals � and �(see Figure19, item �) will cause a soft lockout(automaticreset).Whenlimit(s)closes,boilerwillresumenormaloperation.
�. Controls connected between terminals � and 8(seeFigure19, item�).willcauseahard lockout(manual reset). The boiler will only restart aftertheUltradisplaypanelRESETswitchispressed.
2. Pressthe“+”or“-”buttontochangethesettingtothedesiredoutletwatertemperature.(Thefactorydefaultsettingis190°F.)a. Outdoor sensor installed — Setting is the target
temperature for outdoor temperature at or below�2°F.Athigheroutsidetemperatures,the PhDcontrolmodulecalculatesthetargettemperature.(See
�. The PhDcontrolmoduleturnsonthePLUScirculatorwhentheindirectwaterheateroperatingcontrol closes.Thecontrolmodule shutsoff theboilercirculator(stopsspaceheating)duringcallsforDHWheating.
Verify space heating operationNOTE:“[ _ _ _ _ ]” in the following indicates thecharactersthatshouldshowonthe displaypanel.“180”intheright�placesmeansthedisplayshowsthemeasuredboilerwatertemperature.Thenumbershownwillnotnecessarilybe180.
[2180] (ignition)After prepurge, the control moduleopensthegasvalveandstartsignitionspark.
a. Ifburnerflameproveswithin�.�seconds,burnercontinues to fire. Burner will fire at start-uprate—�0%ofmaximuminput—forabout10secondstoallowflametostabilize.
b. Ifburnerflamedoesnotprovewithin�.�sec-onds,controlmoduleattemptsignitionsequenceagain.Flamemustprovewithin�attemptsorcontrolwilllockout(displaywillshow[E 02]).
c. Verifyflamefailureoperationbyclosingboilermanual gas cock to prevent gas flow. Openmanualgasvalveaftertesting.
�� Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
Start-up — Gas boilers only (continued)B4Gas
[3180](burner on, space heating)Onceflameisprovenandstable,theburnerturnsdowntolowfireforap-proximately2minutes.
• After this low fire period, the burner is allowed tomodulate.Firingratedependsonactualoutletwatertemperatureversustargettemperature.
[6180](target temperature reached)Theburnerwillshutdown.Theblowerwillruninpostpurge(seebelow),thenturnoff.Theboilercirculatorcontinuestorunaslongasthereisacallforheat.
[1180] (prepurge) Blower speed will increase to igni-tionspeed.Theblowerwill run inprepurge for10seconds.
[2180] (ignition)After prepurge, the control moduleopensthegasvalveandstartsignitionspark.
a. Ifburnerflameproveswithin�.�seconds,burnercontinues to fire. Burner will fire at start-uprate—�0%ofmaximuminput—forabout10secondstoallowflametostabilize.
b. Ifburnerflamedoesnotprovewithin�.�sec-onds,controlmoduleattemptsignitionsequenceagain.Flamemustprovewithin�attemptsorcontrolwilllockout(displaywillshow[E 02]).
c. Verifyflamefailureoperationbyclosingboilermanualgasvalvetopreventgasflow.Opengascockaftertesting.
[4180] (burner on, PLUS) Once flame is proven andstable,theburnerisallowedtomodulate.Firingratedepends on actual outlet water temperature versustargettemperature.
[6180](target temperature reached)Theburnerwillshutdown.Theblowerwillruninpostpurge(seebelow),thenturnoff.ThePLUScirculatorcontinuestorunaslongasthereisacallforPLUSheating.
Replace boiler jacket front door afterinstallationorservicing.Theboilerfrontdoor must be securely fastened to theboiler to prevent boiler from drawingairfrominsidetheboilerroom.Thisisparticularly important if the boiler islocatedinthesameroomasotherappli-ances.Failuretokeepthedoorsecurelyfastenedcouldresultinseverepersonalinjuryordeath.
Thissectionprovidessuggestedboiler-sideandsystempipingforboilersotherthan Gas-fired boilers (seeSection B for Gas applications).Youwillfindsuggestedpipingfor:
MultiplewaterheaterapplicationsMultiple water heaters – water heater piping — Figures 26/27 ................................ 42Boiler water piping for multiple water heaters — Figure 28 ..................................... 43
1. Thisdrawingisconceptualonly.Itshowsrepresentativepipingcomponentsandlayout.Weil-McLaindoesnot represent that thisdrawingmeetsanyparticularmechanicalorbuildingcodes.Theinstallerisresponsibleforinclusionofallrequiredsafetydevices,orothermiscellaneouspipinghardwarenotshownondrawing.Theinstallerisresponsibleforpropersizing/selectionofallhardwareshownonthisdiagram.
1. Thisdrawingisconceptualonly.Itshowsrepresentativepipingcomponentsandlayout.Weil-McLaindoesnot represent that thisdrawingmeetsanyparticularmechanicalorbuildingcodes.Theinstallerisresponsibleforinclusionofallrequiredsafetydevices,orothermiscellaneouspipinghardwarenotshownondrawing.Theinstallerisresponsibleforpropersizing/selectionofallhardwareshownonthisdiagram.
1. Thisdrawingisconceptualonly.Itshowsrepresentativepipingcomponentsandlayout.Weil-McLaindoesnot represent that thisdrawingmeetsanyparticularmechanicalorbuildingcodes.Theinstallerisresponsibleforinclusionofallrequiredsafetydevices,orothermiscellaneouspipinghardwarenotshownondrawing.Theinstallerisresponsibleforpropersizing/selectionofallhardwareshownonthisdiagram.
1. Thisdrawingisconceptualonly.Itshowsrepresentativepipingcomponentsandlayout.Weil-McLaindoesnot represent that thisdrawingmeetsanyparticularmechanicalorbuildingcodes.Theinstallerisresponsibleforinclusionofallrequiredsafetydevices,orothermiscellaneouspipinghardwarenotshownondrawing.Theinstallerisresponsibleforpropersizing/selectionofallhardwareshownonthisdiagram.
Installation and start-up of water heaters connected to steam boilersSeeFigure29,page��,forsuggestedpipingschematic.PipethedomesticwaterconnectionstothewaterheaterperSectionAofthismanual.• Boiler connections for the water heater must be
Connecting water heater to steam boilerWhen designing steam and domestic hot water sys-tems, there are some key issues that must be takenintoconsiderationduringtheinitialdesignphase.Bydesigningthesystemproperlyfromthestart,youcanavoidproblemsandhaveahotwaterloopinasteamboilersystem.
Special considerations:• Keepthelooptemperaturebelowtheflashpoint.
• Supply from a tapping that is high enough topreventintroducingsedimentintothepipingandcirculatoryetstillpositionsthecirculatorbelowthewaterline.Avoidthemudlegoftheboiler.
ON STEAM BOILER APPLICATIONS ONLY—Youmustreplacetheautomaticairventsuppliedwiththewaterheaterwithamanualairvent.Failuretodosocouldresultinseverepersonalinjury,deathorsubstantialpropertydamage.
Useballvalve� toblendsomeofthe water returning to the boilerwiththehotwatercomingfromtheboiler.Thiswillreducethepossibil-ity of flashing (cavitation) in thecirculator.Slowlyopenvalve�untiltemperaturegauge8reads200°F.
Lock or remove the handle fromvalve�afteradjusting.
�� Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
wirinGrequirements .............................................................................................. 47Wiring requirements — Circulators ........................................................................... 47Wiring requirements — Zone Valves ......................................................................... 47Boiler models requiring domestic priority with GOLD Plus 30 ................................ 47
Zoningwith4-wirezonevalves• No domestic priority ............................................................................................... 53• With or without priority • GOLD Plus 30/40/60/80 or Plus 40/60/80 ......... 55• With domestic priority • PLUS 100/110/119 ....................................................... 57• With domestic priority using 2-way priority valve • PLUS 100/110/119 ........... 58
Zoningwith3-wirezonevalves• No domestic priority ............................................................................................... 54• With or without priority • GOLD Plus 30/40/60/80 or Plus 40/60/80 ......... 56• With domestic priority • PLUS 100/110/119 ....................................................... 57• With domestic priority using 2-way priority valve ................................................. 59
B. PLUS100,110or119 ..................................................................................................................................... 52
Residential & Commercial Cast Iron Boilers Residential Water Warranty — Limited Lifetime Residential Steam Warranty — Limited 10 Year Commercial Warranty — Limited 10 Year
First Year — (All Residential & Commercial Cast Iron Boilers) Weil-McLainwarrants that its cast iron boilers are free from defects in material and workman-ship for one year from date of installation. If any parts are found to be defectivefrom such defects, Weil-McLain will provide replacement of such defective parts.
Second Through Tenth Year — (Residential & Commercial Water/Steam)Weil-McLain warrants that the cast iron sections of its water and steam boilers arefree from defects in material and workmanship from the date of installation for thesecond through the tenth year. If, during such time, any section is found to bedefective, Weil-McLain will provide replacement of such defective section(s).
Eleventh Year and Beyond — (Residential Water Only) Weil-McLain warrantsthat the cast iron sections of its residential water boilers are free from defects inmaterial and workmanship for the eleventh year and beyond from the date ofinstallation. If, during such time period, any section(s) is found to be defective,Weil-McLain will provide replacement of such defective section(s) upon thepayment of a proportionate charge based on the time the boiler has been inservice. The proportionate charge will be equal to the appropriate percentage ofthe list price of such section(s) at the time the warranty claim is made, and will bedetermined as follows: 11th year-5%; 12th year-10%; 13th year-15%; 14th year-20%; 15th year-25%; 16th year-30%; 17th year-35%; 18th year-40%; 19th year-45%; 20th year-50%; 21st year-55%; 22nd year-60%; 23rd year-65%; 24th year-70%; 25th year & beyond -75%.
These warranties do not cover boilers operated with combustion air contam-inated externally by chemical vapors or with improper fuel additives, or with waterconditions which may have caused unusual deposits in the cast iron sections.
See section “For all Weil-McLain Products” for additional warranty information.
Weil-McLain Limited Warranties
NOTE: Residential warranties do not cover any residential products installed in build-ings other than one or two family dwelling units, unless they are buildings with indi-vidual residential products for each dwelling unit.
THE WARRANTIES DESCRIBED HEREIN ARE IN LIEU OF ALL OTHER WAR-RANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IM-PLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MER-CHANTABILITY. WEIL-McLAIN EXPRESSLY DISCLAIMS AND EXCLUDES ANYLIABILITY FOR CONSEQUENTIAL, INCIDENTAL, INDIRECT OR PUNITIVE DAM-AGES FOR BREACH OF ANY EXPRESS WARRANTY. For prompt product war-ranty claims, notify the installer who, in turn, will notify the Weil-McLain distributorfrom whom he purchased the boiler. If this action does not result in warranty resolu-tion, contact Weil-McLain Consumer Relations Department, 500 Blaine Street, Michi-gan City, Indiana 46360, with details in support of the warranty claim. Alleged defec-tive part or parts must be returned through the same trade channel in accordancewith the Weil-McLain procedure currently in force for handling returned goods for thepurpose of inspection to determine cause of failure. Weil-McLain will furnish newpart(s) to an authorized Weil-McLain distributor who, in turn will furnish the new part(s) to the heating contractor who installed the boiler. If you have any questions aboutthe coverage of this warranty, contact Weil-McLain at the address above.
Indirect-Fired Water Heaters Residential Water Heater Warranty — Limited Lifetime Commercial Water Heater Warranty — Limited 15 Year
First Year — (Residential and Commercial Water Heaters) Weil-McLain warrantsthat its indirect-fired water heaters are free from defects in material and workmanshipfor one year from the date of installation. If any parts are found to be defective fromsuch defects, Weil-McLain will provide replacement of such defective parts.
Second Year and Beyond — (Residential Only)Second Through Fifth Years — (Commercial Only)Weil-McLain warrants that the tank assembly components of its indirect-fired waterheaters are free from defects in material and workmanship for the second throughthe fifth year from the date of installation (commercial only), or for the second yearfrom the date of installation and beyond (for residential only). If, during such timeperiods, a leak in the tank assembly should occur, Weil-McLain will provide replace-ment for the original tank assembly.
Sixth Year through Fifteenth Year — (Commercial Only) Weil-McLain warrantsthat the tank assembly components of its commercial indirect-fired water heaters arefree from defects in material and workmanship for the sixth year through the fifteenthyear following the date of installation. If, during such time period, a leak in the tankassembly should occur, Weil-McLain will provide replacement for such defective tankassembly. Such replacement will be furnished with the nearest comparable modelavailable from Weil-McLain at the time of such replacement and upon payment of aproportionate charge. Proportionate charges will be equal to the appropriate percent-age of the current list price of such commercial indirect-fired water heater at the timewarranty claim is made and will be determined as follows: 6th & 7th year-55%; 8th &9th year-60%; 10th & 11th year-65%; 12th & 13th year-70%; 14th & 15th year-75%.
These warranties do not cover:1. Any water heater not initially installed with a new temperature-pressure relief valve
bearing the listing of the American Society of Mechanical Engineers (A.S.M.E.) at thetime of the water heater installation.
2. Any water heater that has a failure or malfunction resulting from a.) failure to keep thetank full of potable water; b.) failure to assure that water in the tank is free to circulateat all times; or c.) failure to keep the tank free of water sediment or scale deposits.
3. Any water heater that has potable water in the unit with a chloride or chlorine contenthigher than 80 mg/liter.
4. Any water heater installed in a residence containing any type of water softener systemthat is not installed and maintained in accordance with manufacturer’s specifications.
5. Any water heater installation where non-metallic piping products without an oxygenbarrier are used.
6. Any water heater used for non-potable application such as pool or process heating.
See section “For all Weil-McLain Products” for additional warranty information.
Commercial Warranty — Limited 15 Year (does NOT include Ultra HPP)
First Through Fifth Year — Weil-McLain warrants that its cast aluminum boilersare free from defects in material and workmanship for one year from the date ofinstallation and the heat exchanger is free from defects in material andworkmanship for five years from the date of installation. If any parts in the firstyear, or the heat exchanger in the first five years are found to be defective fromsuch defects, Weil-McLain will provide replacement of such defective parts or heatexchanger. In addition to the product warranty, Weil-McLain will provide a 5-Year “Ultra”Homeowner Protection Plan (“UHPP”) for residential applications only to cover parts and laborfor five years from the date of installation provided only if the Ultra boiler is properly registeredwith the UHPP Administrator within one month of the date of installation. UHPP claims must beprocessed directly through thePlan Administrator and not through Weil-McLain.
Sixth Through Tenth Year — Weil-McLain warrants that the heat exchangers ofits cast aluminum boilers are free from defects in material and workmanship forthe sixth through the tenth year from the date of installation. If, during such time,the heat exchanger is found to be defective, Weil-McLain will provide replacementof such defective heat exchanger.
Eleventh Through Fifteenth Year — Weil-McLain warrants that the heatexchangers of its cast aluminum boilers are free from defects in material andworkmanship for the eleventh through fifteenth year from the date of installation.If, during such time period, the heat exchanger is found to be defective, Weil-McLain will provide replacement for such defective heat exchanger upon thepayment of a proportionate charge based on the time the boiler has been inservice. The proportionate charge will be equal to the appropriate percentage ofthe list price of such heat exchanger at the time the warranty claim is made, andwill be determined as follows: 11t h year - 10%; 12th year - 20%; 13th year -40%; 14th year - 60%; 15th year - 80%; 16th year & beyond - 100%.
This warranty does not cover boilers operated with combustion air contaminatedexternally by chemical vapors or with improper fuel additives, or with water/system conditions which may have caused heat exchanger failure.
See section “For all Weil-McLain Products” for additional warranty information.
Radiant Heating Products Radiant Heating Products Warranty — Limited 30 Year IPP & IPC Products Warranty — Limited 3 Year
Weil-McLain warrants that its AlumiPex and Qual-Pex radiant heating products arefree from defects in material and workmanship for thirty years (three years for IPPand IPC products) from the date of installation. If any parts are found to be defectivefrom such defects during such time period, Weil-McLain will provide replacement ofsuch defective parts. It is expressly understood that failure as a result of freezing ofwater within the pipes (tubing) does not constitute a defect in material orworkmanship and shall not be covered by this warranty.See section “For all Weil-McLain Products” for additional warranty information.
Parts and Accessories Parts and Accessories Warranty — Limited 1 Year
Weil-McLain warrants that parts and accessories that were purchased through Weil-McLain are free from defects in material and workmanship for one year from the dateof installation. If any parts and/or accessories are found to be defective from suchdefects during such time period, Weil-McLain will provide replacement of suchdefective parts. Parts and accessories covered under this warranty include onlythose items that are not covered under other Weil-McLain product warranties.See section “For all Weil-McLain Products” for additional warranty information.
For All Weil-McLain Products: These warranties are subject to the conditionthat the Weil-McLain Product(s) must have been installed in accordance withmanufacturers’ instructions by a heating contractor whose principal occupation isthe sale and installation of plumbing, heating and/or air conditioning equipment.These warranties extend only to the first retail purchaser of the products and onlyto a product that has not been moved from its original installation site.
In addition to each product warranty listed, Weil-McLain warranties do not cover:1. Components that are part of the heating system (products) but were not fur-
nished by Weil-McLain as a part of the heating system (products).2. The workmanship of any installer of Weil-McLain’s product(s). In addition, this
warranty does not assume any liability of any nature for unsatisfactory perform-ance caused by improper installation.
3. Any costs for labor for removal and reinstallation of the alleged defective part,transportation to Weil-McLain, if necessary, and any other materials necessaryto perform the exchange.
4. Any products that have a failure or malfunction resulting from improper ornegligent operation, accident, abuse, freezing, misuse, unauthorized alterationor improper repair or maintenance.
5. Improper adjustments (including boiler/burner), control settings, care or mainte-nance. Information is in the installation, start-up, operations, owner/user’smanuals, service/maintenance instructions, and other printed/technical informa-tion provided with the product or direct from Weil-McLain or weil-mclain.com.